APEX Automation & Robotics has just completed the installation and commissioning of four Robotic Palletisers for a leading food manufacturer. Integrated with AGVs to load and unload pallets, each robotic palletiser can run up to 12x SKUs with different palletising patterns, without any adjustments to the robotic heads, producing a total of more than 5000 cartons/hr.
As cartons exit the case packers, they are transferred on low friction accumulation conveyors to the four robotic cells where they are collated and palletised.
Designed and built to the meet GMP requirements, each robotic cell contains:
- Collating station and load forming
- 6-axis robot
- Bin for the slip sheets
- Two pallets conveyors
Pallets are loaded by an AGV. They move on the pallet conveyors to the palletising stations where they are aligned and clamped in position throughout the palletising process. When a pallet is full on one conveyor, it is transferred back to the front of the conveyor to be picked up by the AGV, whilst the robot works on the other conveyor.
Each robot has a proprietary end-of-arm tool featuring a sectioned vacuum head capable of handling single or multiple cartons (up to six) on the fly, along with expanding arms that open to pick up slip sheets and place them onto pallets. The palletising positions for different products are pre-programmed, and once the product is selected, the robot follows the corresponding recipe. The robot is capable of “split-placing” by palletising half of the picked load in one position and the other half in a different position, resulting in a faster operation.
The system is controlled by a PLC and a user-friendly HMI interfacing with the robot controllers and the AGVs.
Each robotic cell is fully guarded with perimeter fencing and interlocked safety doors in accordance to the relevant Australian standards, in particular AS 4024.3301-2017 – Safety Requirements for Industrial Robots. The safety circuit includes light curtains and muting sensors connected to a Programmable Safety Controller (Safety PLC).
Apex Automation and Robotics delivers automation solutions tailored to each client’s needs, helping Australian manufacturers remain flexible, efficient, and competitive.
